T-MAN LIGHTING TOWER SHINING A LIGHT ON SAFETY Brian Edwards Plant and Asset Operations Manager Australia and Pacific
BACKGROUND At any given time up to 60 separate 240V lighting plants can be operational on an active mine site. Each lighting tower required constant manual handling, physical interaction with heavy and light vehicles, monitoring and maintenance.
PROBLEM 240V lighting towers expose staff to electrical circuits Require 240V electricians for maintenance Require constant: manual handling monitoring maintenance mobilisation/demobilisation refuelling in person start up and switch off limited light dispersal.
HAZARDS Electrocution Possible Fatality Interaction with light and heavy vehicles /accidents Possible Fatality Handling broken glass bulbs – lacerations Minor - Serious Injury Exposure to harmful gases (mercury, metal halides) Minor – Serious Injury Manual handling – musculoskeletal disorders (MSDs) Minor – Serious Injury
SOLUTION Substitute 240V for 24V Decrease bulb replacement Match or increase lighting output Reduce plant engine size, fuel consumption, servicing and refuelling frequency Recycle old lighting plant frames, axles, wheels and hydraulics Satellite monitoring. Collaboration Partners HAYNES Group - provided workshop facilities, components and materials Auxilium Systems - provided components and satellite tracking software.
SATELLITE MONITORING SYSTEM Mobile Plant Management (MPM) by Auxilium is available on both mobile application and PC. Light tower functions monitored by MPM: Remote engine start Remote engine stop Location Engine hours KM travelled Towing speed Fuel levels Carbon foot print. Subscribed alerts: Engine maintenance schedule.
vs 240V METAL HALIDE 24V LED 6 HEADER LIGHT TOWER 6 HEADER LIGHT TOWER
Dual Axle Lighting Tower
OPERATIONAL BENEFITS Increased light output by 51,600K per dual axle tower Increased engine life 20,000hrs Increased lamp life to 50,000hrs Reduced engine and trailer weight - increased mobility Reduced refuelling frequency from every 3 days to once a month Reduced annual carbon emission saving 26,600 CO2kg per dual axle Reduced manufacturing costs – recycling old parts Long-term financial benefits were achieved from reduced fuel consumption, part replacements and maintenance.
REDUCED HAZARDS 240V electrical circuits down to 24V Substituted Heavy and light vehicle interaction Reduced Exposure to harmful gases (mercury, metal halides) Reduced Manual handling – musculoskeletal disorders (MSDs) Reduced Lacerations - handling broken glass bulbs Reduced
COST BENEFITS Outlay per dual axle tower $17,745 Annual savings per dual axle tower $34,824 Total outlay (160 T-MAN towers) $2,718,880 Total annual savings (160 towers) $5,399,040
TRANSFERABILITY The whole innovation or individual elements can be transferred across the industry. Satellite Monitoring System (MPM by Auxilium) Vehicle and maintenance monitoring for trucks on site Minimise heavy and light vehicle interaction Monitoring other ancillary equipment Monitor breakdowns Monitor shutdowns for maintenance Monitor ramp traffic and vehicle routes. 240V to 24V generator conversion Concept applied for air conditioners and other small motors Old lighting plant can be converted/recycled – increased asset lifespan.
The T-MAN Lighting Tower Refurbishment Program has exceeded all expectations delivered increased safety by reducing interaction with live plant, and minimised manual handling hazards . The program has also increased productivity and reduced running costs . Over 160 Thiess owned T-MAN lighting towers have successfully been converted across Thiess’ Australian operations Thiess is currently exploring opportunities to apply this technology across its global operations. T-MAN – Thiess manufactured
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